THE BIHL+WIEDEMANN MAGAZINE

BIHL-WIEDEMANN.DE n YEAR 06 n EDITION 01.2012

THE AS-INTERFACE MASTERS

POTENTIALS FOR SAVINGS IN SAFETY TECHNOLOGY

THE COORDINATES OF EFFICIENCY

INTERVIEW

„It’s not about systems, rathersolutions“

Collect up to 1922 safe 2-channel input signals cost-effectively, control safe outputs in a centralized or decentralized way

GATEWAYS WITH SAFELINK

Collect and evaluate up to 62 safe signals with one module

GATEWAYS WITH INTEGRATED SAFETY MONITOR

SAFETY BASIC MONITORIt is economical with only 3 safe signals

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Regardless of whether you are dealing with complex and distributed systems, medium-size applications with 10 to 100 safe in- and outputs, or small machines with just 3 to 10 safe signals: the right safety concept promises considerable potential for savings on any level – usually with the added bonus of performance and security. Here the safety specialists from Bihl+Wiedemann have developed the optimal solutions – under the motto “efficiency á la carte.”

The Coordinates of EfficiencyPotentials for savings in safety technology

SAFETYAS-INTERFACE

Safety technology for all system sizes

In German-speaking countries it’s long been a legend, and meanwhile its existence has even become official, with an entry in the standard reference book of German expressions: the egg-laying wool-milk-pig. The dictionary of German idioms defines it as a colloquial expression for something – a person or problem solution – that “offers only advantages, satisfies all needs, meets all requirements”.

And why are we telling you this? Simple: because these traits of the multi-talented mythical beast have clear parallels with those of the safety concepts from Bihl+Wiedemann: they too meet all the safety requirements placed on today’s modern equipment – irrespective of the scope and particular control system of the application. And they also offer only advan-tages: with respect to cost as well as to the specific performance features.

The trend towards ever more complex, dis-tributed applications continues to speed up both in factory and process automation. Among the special challenges in the safety area is the most efficient possible coupling of safe networks. Previous coupling solu-tions have included floating contacts or directly over AS-Interface – but all these also had a downside: in the one case it was the relatively cumbersome wiring, in the other the fact that one AS-i circuit per Gateway was lost for safe coupling.

At SPS/IPC/DRIVES 2011 in Nuremberg Bihl+Wiedemann presented their amaz-ingly simple and above all surprisingly cost-effective solution: SafeLink over the Ethernet diagnostic interface of the newest AS-i Gateway generation with integrated Safety Monitor. In the maximum configura-tion this allows you to collect up to 1922 safe 2-channel input signals and control safe outputs either centrally or remotely.

These innovative devices automatically and continuously exchange the in- and output data from all the connected machines and make the data available to the respective program. This approach allows up to 31 of the new Gateways with integrated Safety Monitor to be coupled together – without losing performance at any point and with-out the use of additional hardware.

This unbeatably lean solution is attractive not only for the larger, pure safety appli-cations such as found in machine building. An enormous savings potential is also there for users who want to profit from a decisive benefit of AS-Interface: the ability to send safe and non-safe signals over the same two wires. Because of course the number of slaves to be incorporated rises when standard AS-i is combined with AS-i Safety.

The demand for efficiency has also been long increasing in the large number of

medium-size safety applications, for sys-tems with 10 to 100 safe in- and outputs. More and more users are recognizing the numerous advantages of the innovative safety concepts from Bihl+Wiedemann compared both with traditional safety relays as well as with safety controllers. The two most important plus points for the AS-i Gateways with integrated Safety Mo-nitor, which can collect and process up to 62 safe signals, are the incomparably simple wiring and the optimal interface to the systems commonly used in automation.

The small safety controllers in a control cabinet can almost keep up when it comes to cabling – but in the field they have to be conventionally and tediously wired. All the safe AS-i components need is direct con-nection using the famous yellow cable. This trump card gets played not only at the time of initial installation, but also when the time comes for expansions or reconfigurations of the system. Whereas the use of safety controllers requires that additional cable be routed and old cable may need to be removed every time there is a minor modi-fication to the system, AS-i makes it simple: Disconnect – connect – you’re done!

Users also profit in many aspects from the outstanding team player qualities of AS-Interface when used together with other automation systems. Whether PROFIBUS, PROFINET or PROFIsafe, whether Ether-CAT, sercos, EtherNet/IP or Modbus over Ethernet: thanks to expanded diagnostic functions, complete shut-off history and detailed, gapless status information for all

For large, distributed systems: SafeLink over Ethernet

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SAFETYAS-INTERFACE

For medium-size systems: Gate-ways with integrated Safety Moni-tor and optimal interface to com-mon control systems

SWITCH

- Safety Ethernet, SafeLink

- Max. 31 Gateways

- 31 Safety Bits per Gateway

- Everyone hears everyone

- Safe coupling over Ethernet

- The simplest way of coupling many safe signals

- Up to 1922 safe AS-i slaves

Large Systems

Large systems: Gateways with SafeLink over Ethernet diagnostic interface

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AS-i components, the host controller can respond even faster to faults and signifi-cantly reduce downtimes. But not only ma-chine availability, safety itself also benefits from the partner-like relationship between AS-Interface and the controller: the sensi-tive safety data are – without cumbersome parameterization – automatically transmit-ted to the standard controller in real time, allowing it for example to introduce con-trolled powerdown of a system before it is completely shut off by the safety technology.

Until recently it was still a favorite calcu-lating exercise: both safety technology providers and their customers kept making

new calculations for the system size cut-off point where good oled parallel wiring should finally be dispensed by AS-i Safety. The question has now been answered once and for all – even setting aside the numer-ous functional virtues of a bus system: today AS-i Safety resolves even the pure cost consideration in its own favor even for systems with just 3 or more safe signals.

There are two main reasons for this. First, since the introduction of AS-i Power24V it is now possible to eliminate the additional AS-i power supply in very small applica-tions. Secondly, Bihl+Wiedemann now offers a new cost brake with their Safety Basic Monitor. Like its bigger brother, the unit consists of a safety monitor and a selectable AS-i Master, but otherwise it has been developed according to the “reduce to the max” philosophy. For example it does

not include a fieldbus interface, but rather just indication outputs for communicating with any host controller which may be pres-ent. And its inner sanctum is enclosed not in the rugged stainless steel housing, but rather in a slim IP20 plastic one. Keeping pace with the selection of custom-tailored safety concepts for systems of any size, Bihl+Wiedemann has also expanded their offering of corresponding applica-tion components. These range from ver-satile in and output modules to optimized software solutions to high-performance Speed Monitors and E-stop Buttons. By now there is hardly anything lacking in the safety portfolio of the safety specialists from Mannheim. And one thing comes standard with every order: the efficiency that is universally demanded in the world of safety.

For small systems: Safety Basic Monitor with switchable AS-i Mas-ter capability – the new cost brake for 3 safe signals or more

- 2 (4) safe electronic outputs onboard

- 8 / 4 safe inputs or

8 standard inputs and 8 indication outputs

- Chip Card for easy device replacement

- 1 AS-i Master + Safety Monitior

Small systems

Expansion modules22,5 mm

2 wires

AS-i

Medium-size systems: Gateway with integrated Safety Monitor and expansion modules

Small systems: Safety Basic Monitor and expansion modules

2 wires

AS-i 2AS-i 1

- Optimal PLC connection via fieldbus

- All diagnostic data in the controller

- Safety and standard signals mixed

- Max. 62 safe modules

- Safe sensors of many vendors via AS-i

- Low installation costs for further modules

Medium-size systems

SAFETYAS-INTERFACE

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INTERVIEWAS-INTERFACE

Interview with Jochen Bihl,CEO of Bihl+Wiedemann GmbH

In 1995 Bihl+Wiedemann was the first company to offer a certified AS-i Master, and today they remain one of the pioneers of AS-Interface. That the Mannheim based firm is now also considered a universal safety specialist is not, according to Jochen Bihl, a contradiction but rather a logical progression.

„It’s not about systems,rather solutions“

AS-i MASTER NEWS: Mr. Bihl, for over 15 years the equation “Bihl+Wiedemann = AS-i” has been applied to your company within the world of automation. But recently you have been seen increasingly as a universal safety specialist. Is the company known as the “AS-Interface Masters” losing their focus?

JOCHEN BIHL: No, not in the slightest. The fact that we no longer raise the AS-i flag quite so high when we talk about cus-

tom-tailored safety has a totally pragmatic reason: our customers, present and future, expect above all concrete technological answers to concrete technological ques-tions. While our concepts are based on AS-i Safety, this is relevant in essence only for applications with AS-Interface running in the standard area as well, since this is of course where additional savings potential can be realized. For all the other customers it’s not about systems, but rather solutions. Whether these solutions work best with AS-i, BS-i or CS-i doesn’t really matter.

AS-i MASTER NEWS: But suppose it does to us. Are you in a position now to bundle safety packages that will run with systems other than AS-i Safety?

JOCHEN BIHL: Naturally we have the nec-essary know-how to accomplish this – but in practical terms we have never yet been faced with a situation where this actually made sense. From a pure system point of view AS-Interface Safety at Work is at pres-ent simply the non plus ultra when it comes to modern safety technology – and will in all probability remain so for a long time to come. There is for example no other technology that so consistently address-es the trend towards decentralization. Besides, our range of versatile expansion modules and optimized software solutions has become so large that there is virtu-

ally no safety issue today that we cannot respond to with AS-i Safety.

AS-i MASTER NEWS: You have in fact been causing quite a stir recently with your safety technology innovations. Will you be concentrating to the same degree in the future on further developing AS-Interface for non-safety applications?

JOCHEN BIHL: At no point have we di-minished our efforts in this regard. It is possible that over the past one or two years the standard applications have been over-shadowed by our new safety products, but a lot has happened de facto for non-safety applications as the new products have been introduced. Consider for example the numerous additional diagnostics features or the additional PLC function of our new-est Gateways which can be programmed in C and are therefore ideally situated for the demands of tomorrow. Differentiating according to safety and standard products is not a huge factor when we consider the next safety and standard products. The decisive factor is always what challenges our customers are currently facing – and what technological means we can offer to meet them in the best and simplest way possible.

AS-i MASTER NEWS: Mr. Bihl, thank you for speaking with us.

More new Bihl+Wiedemann products

DEVELOPMENTAS-INTERFACE

AS-i 3.0 PROFINET Gateway with integrated Safety Monitor now with SafeLink (BWU2642) n Besides the PROFIBUS Gateways also PROFINET

Gateways are now available with Safe-Link n SafeLink over PROFINET: 3 Efficient and cost-effective collecting and processing of up to 1922 safe 2-channel input signals 3 Cen-

tralized or decentralized control of safe outputs 3 Simple configuration 3 Up to 992 safe inde-pendent outputs possible n The unit also offers the familiar advantages of the PROFINET Safety Gateways from Bihl+Wiedemann, e.g.: 3 High cost-effectiveness from up-front cost savings, in-stallation effort and control cabinet space as well as the ability to easily exchange units and rapid commissioning thanks to the Chip Card 3 High efficiency from monitoring of the release circuits up to SIL3/Cat4/PLe while offering expanded Bihl+Wiedemann AS-i diagnostics including Rec-ognition of duplicate AS-i addresses, AS-i Earth

Fault Detector and AS-i Noise Detector in a single housing 3 Up to 62 safe I/Os per device

Safety Basic Monitor with enhanced functionality (BWU2569)n Completes the standard version (BWU2441) and the version as fully compatible ad-vancement of the AS-i consor-tial Safety Monitor (BWU2567)n Enhanced functionality: 3 8 safe release circuits plus

AS-INTERFACE HIGHLIGHTDigital Modules AS-i now also in IP20 (22,5mm) and IP67

3 With 4 or 8 digital inputs respectively 4 or 8 digital outputs 3 AS-i Slave Type: 1 AB Slave or 2 AB Slaves 3 Inputs and outputs powered from external 24V 3 Cost-effective IP20 solution

In addition to the Stainless Steel housing version, digital I/O modules are now also available in various models in the just 22,5mm wide IP20 housing and in the IP67 housing.

n Digital Modules AS-i in IP20, 22,5mm:

n Digital Modules AS-i in IP67, M12:

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Digital Modules AS-i in IP67, M12

2x2 terminations for AS-i in yellow cable / Bicolor LED per outputCost-effective IP20 solution

Digital Modules AS-i in IP20, 22,5mm

Robust housing solution for cabinet mounting

Digital Modules AS-i in Stainless Steel, IP20

3 Compact housing versions: 4I, 4O, 4I/4O; Large housing versions: 8I, 8O, 4I/4O 3 AS-i Slave-Typ: 1 AB Slave, 2 AB Slaves 3 M12 interface: Single-interface or Y-interface 3 Input voltage (sensor supply) from AS-i or AUX 3 AS-i / AUX connection via 2-conductor unshielded AS-i yellow cable (2x2 terminations, penetration technique) or M12 female 3 Bicolor LED per output: State (yellow), Overload (red)

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DEVELOPMENTAS-INTERFACE

AS-i Safety Input Module IP67, M12, for floating contacts now also with 4 / 2 safe inputs (BWU2631)

n Enhances the line of AS-i Safety Input Mod-ules for optoelectronic safety devices or floating contacts with IP67 protection n Ideal comple-ment to the Safety Monitors and AS-i 3.0 Safety Gateways n Space-saving, cost-effective solu-tion: 4 / 2 safe inputs for floating contacts (2 x BWU2284) in one module n Supports applica-tions up to SIL3/Cat4/PLe

AS-i Safety Input Module in IP20 now also for safety mats (BWU2661)n Enhances the line of AS-i Safety Input Modules for op-toelectronic safety devices or floating contacts with IP20 protection n 1 safe input for safety mats 1.2 kΩ or 8.2 kΩ monitoring resistor n 2 conventional semiconduc-tor outputs: short circuit and

overload protected; for controlling up to 2 indica-tor lights; powered by galvanically separated 24V

advantages of Gateways with inte-grated Safe-ty Monitor for fieldbus-es such as PROF IBUS, P R O F I N E T, E t h e r C AT, M O D B U S TCP and

EtherNet/IP: 3 High cost-effectiveness from up-front cost savings, installation effort and control cabinet space as well as the ability to easily ex-change units and rapid commissioning thanks to the Chip Card 3 High efficiency from monitoring of the release circuits up to SIL3/Cat4/PLe while offering expanded Bihl+Wiedemann AS-i diag-nostics including Recognition of duplicate AS-i addresses, AS-i Earth Fault Detector and AS-i Noise Detector in a single housing n Single Gate-way with Safety Monitor for 2 AS-i networks, 32 OSSDs n 2 relays and 2 electronic safe outputs n SafeLink over Ethernet diagnostic interface: 3 Efficient and cost-effective collecting and processing of up to 1922 safe 2-channel input signals 3 Centralized or decentralized control of safe outputs 3 Simple configuration 3 Up to 992 safe independent outputs possible

AS-i 3.0 sercos Gateway with integrated Safety Monitor and SafeLink (BWU2588)n Now sercos users can also profit from the

E-stop Button Modules

n AS-i Slave inside the button housing n M12 connection n Simple mounting concept, designed for 40mm profile rails n Available amongst others as: AS-i E-stop Button Module, lighted (BW2529) or unlighted (BW2585), and as AS-i Pushbutton Module with 2 lighted buttons (BW2528)

AS-i CC-Link Gate-way in Stainless Steel (BWU2611)n 1 AS-i Master n Advanced diagnos-tics including: 3 AS-i Earth Fault De-tector 3 AS-i Noise Detector n Enhances the line of Gateways in Stainless Steel to

PROFIBUS, PROFINET, EtherNet/IP, Modbus TCP, EtherCAT etc.

Important new features in the current version of the ASIMON 3 G2 configuration soft-waren Speed Monitor Plugin: User-friendly

configuration, startup and diagnostics of the Speed Monitor: 3 Offline configuration creation and simple, wizard-guided loading of this con-figuration into the units possible 3 Parameters can be read back (as a text file) out of the unit

for documentation 3 Diagnostics for all moni-tored axis n Viewing and configuring SafeLink: 3 Combine multiple Gateways into one project 3 Configure up to 32 release circuits 3 Manage up to 1922 safely coupled signals n Expansion of PROFIsafe mode: View and fully configure pre-processing when using PROFIsafe Gateways n Control standard outputs n New useful system components (e.g. all components are in color)

additional 8 safe release circuits for actuating standard AS-i outputs 3 Antivalent switches 3 Standstill monitors for local inputs n Even more intuitive operation n Even better support using the ASIMON 3 G2 configuration software n 2 (4) safe electronic outputs onboard, 8 / 4 safe inputs or 8 standard inputs and 8 indica-tion outputs with only 22,5mm control cabinet width n Configurable using PC software ASIMON 3 G2 via USB n Universally expandable thanks to integrated AS-i Master using Safety I/O Modules and Standard I/O Modules in IP20 and IP67, AS-i Speed Monitors (up to 40 axis) and Safety Relay Output Modules n Chip Card for easy device re-placement n Uses a 24V power supply

IMPRINT

PublisherBihl+Wiedemann GmbHFlosswoerthstrasse 41D-68199 MannheimPhone: +49 (621) 339960Fax: +49 (621) 3392239info@bihl-wiedemann.comwww.bihl-wiedemann.com

Created byMILANO medien GmbHHanauer Landstraße 196AD-60314 Frankfurt am MainPhone: +49 (69) 48000540Fax: +49 (69) 48000549info@milanomedien.comwww.milanomedien.com

Edited by:Peter Rosenberger Phone: +49 (6251) 7056747 rosenberger@milanomedien.com

BWU2270BWU2284

BWU2631BWU2369BWU2370

BW2529BW2585

BW2528

All products already meet the new

standard + All products already mee

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new

sta

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d +

NEW STANDARD

For large, distributed systems:

Custom tailored safety technology can be this easy.

The various expansion modules can be used for any system size!

Bihl+Wiedemann offers the right concept for any system size.

For medium-size systems: For small systems:

Bihl+Wiedemann GmbH I Phone: +49 (0) 621 339 96-0

More information about our products at:

www.bihl-wiedemann.com

Applications with 10-100 safe I/Os Applications with 3-20 safe I/Os Safe coupling over Ethernet diagnostic interface

Is your system large or widely distributed? Then our units with SafeLink over Ethernet should be your fi rst choice. In their maximum confi guration they provide the ability to collect up to 1922 safe 2-channel inputs cost-effec-tively and effi ciently, and control safe outputs either centrally or remotely.

Are you currently still using conventionally wired safety technology and sometimes need functions which cannot be performed by a sa-fety relay? Then our Safety Basic Monitor is the ideal solution for you. The Safety Basic Monitor provides 8 / 4 safe inputs or 8 standard inputs and 8 indication outputs in an installation width of just 22,5mm.

Gateway with integrated Safety Monitor Gateway with SafeLink Safety Basic Monitor Safety Basic Monitor Starter Kit

Do you build systems that require a higher level of safety and are you looking for simple wiring and an easily confi gurable solution? Then our Gateways with integrated Safety Monitor are the right choice for you. With one unit you can collect and process up to 62 safe signals.

THE AS-INTERFACE MASTERS